Finite Element Modeling of Microstructural Changes in Hard Machining of SAE 8620

Surface and subsurface microstructural characterization after machining operations is a topic of great interest for both academic and industrial research activities. This paper presents a newly developed finite element (FE) model able to describe microstructural evolution and dynamic recrystallization (DRX) during orthogonal hard machining of SAE 8620 steel. In particular, it predicts grain size and hardness variation by implementing a user subroutine involving a hardness-based flow stress and empirical models. The model is validated by comparing its output with the experimental results available in literature at varying the cutting speed, insert geometry and flank wear. The results show a good ability of the customized model to predict the thermo-mechanical and microstructural phenomena taking place during the selected processes.

PRELIMINARY STUDY ON EFFECT OF ROD GEOMETRY IN FHPP BETWEEN FE55006 NODULAR CAST IRON AND SAE 8620 STELL

Nodular cast irons are an excellent alternative in manufacturing process of axels due to their characteristics and good mechanical properties. However, the necessity of joining the axels to the gears and other components, made in carbon steel, is a great challenge. Traditional fusion welding methods applied to dissimilar ferrous materials are not deeply studied. In this context, it is well known that different materials have distinct melting points which can cause difficulty in welding, besides of defects formation from solidification. Therefore, modern joining processes such as Friction Hydro Pillar Processing (FHPP) are a great alternative. In this technology, a consumable rod is rotated against to a base material, generating the heat due to the friction, promoting materials in the plastic state and then producing the weld. Hence, this work presents a preliminary study of FHPP between the FE55006 nodular cast iron and SAE 8620 steel and evaluates the rod geometry influence on microstructure and surface stresses of the welded joints. Two rod geometries were used and two welds were further produced. The results indicated that an increase in the rod contact area promoted a lower surface stress as well as a better welded joint.

Effect of Niobium and Heat Treatment on the Microstructure and Mechanical Properties of SAE 8620 Steel

An interest in the search for materials with reduced thicknesses, high mechanical resistance and low density has been increasing by the industry. The addition of niobium in micro-alloyed steels in the automotive industry is an alternative for obtaining light and resistant materials. The objective of this work was to verify the influence of the niobium and the heat treatment of normalizing in the microstructure and hardness of the steel SAE 8620. Also the behavior of the cementation in the steel was studied. It was verified that the removal of the normalization heat treatment did not affect the microstructure and the hardness of the steel with the niobium in relation to the steel without niobium and normalization. The cemented layer for the steel with niobium presented a greater microhardness to the depth in relation to steel without niobium.

Abrasive effects of sediments on impellers of pumps used for catching raw water

ABSTRACT This study presents an analysis of the abrasive effects of sediments from the bed of the Acre River, Brazil, on the wear of three different ferrous materials employed in the manufacture of impellers of centrifuge pumps used to catch raw water. In order to evaluate the abrasive wear and specific wear coefficient (k) as a function of sediment concentration, tests were conducted in samples of SAE 8620 steel, nodular cast iron and gray cast iron by using a rotary-ball abrasion meter. These tests employed abrasive slurry with concentration of 1, 2, 3, 5 and 10 g L-1 of sediments in distilled water. The volume of worn material as a function of the relative velocity of water flow in relation to the impeller blades was mathematically estimated. The experimental results showed that: i) The semi-angular and semi-rounded shapes of the sediments from the Acre River produced evidence of micro-grooving and plastic deformation in the three metallic alloys; ii) SAE 8620 steel showed higher resistance to abrasive wear than samples of gray and nodular cast iron; iii) the increase in the volume of worn material due to increment in sediment concentration and the relative velocity of the mixture (water + sediment) to the rotor pads.

Experimental Design Applied to the Machining of Windows Cage Ball Joints Homokinetic SAE 8620 Steel with CBN Tool

In this work a factorial planning had been used to evaluate the CBN tool life during cut-ting SAE 8620 steel. Part U2222 of a TPGW 160408 insert of TX-LS TB650 and 2NU-SHMA6942 S7182BN300 classes from two manufacturers were used in this experiment. A 23 factorial design was used In cutting process to evaluate the behavior of the tool life and reason of the exchange of the part on influences of the chamfer (in S and T+S), the advancing speeds (0.09, 0.10 and 0.11 mm/rpm) at a cutting speed of 91.2 m/min. Model have been fit by variance analysis (ANOVA) and the processing optimization was done by response surface methodology (RSM). Results showed that a hyperbolic model had more adjusting than other models and the optimization showed a high life time for the TX-LS TB650 tool from A manufacturer on 0.09 mm/rpm of advancing speed, where it was observed that the pre-cranking was the reason of the exchange.